20Y6 – Suction Pump may Allow Fuel into the EVAP System – 2015-2016 Volkswagen Golf & GTI

SEOCONTENT-START

If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to
the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and
mail it to us so we can update our records.
20Y6 USA_INTERIM
IMPORTANT SAFETY RECALL
Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326

This notice applies to your vehicle:
NHTSA: 16V647
IMPORTANT!
Information about Safety Recall 20Y6 – Suction Pump
Your vehicle is affected by the safety recall described in this letter; however, due to limited parts
supply, your dealer may not be able to perform the recall work for you at this time. In the interim, if
you have any concerns about driving your vehicle, or if you smell fuel in the vehicle, make an appointment
with your authorized Volkswagen dealer to have the vehicle inspected/repaired without delay.
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2016
model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show you are the owner of a
vehicle affected by this recall.
Recall Description: On certain vehicles, the suction pump inside the fuel tank designed to purge fuel
from the evaporative emissions (EVAP) system may have been damaged during assembly. This could
cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak
through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, could lead
to a fire causing injury and/or damage to property.
Precautions You Should Take: If you smell fuel in the vehicle, make an appointment with your
authorized Volkswagen dealer to have the vehicle inspected without delay.
Additionally, you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback)
when fuel accumulates in the EVAP system. If this happens, immediately contact the nearest authorized
Volkswagen dealer to have the vehicle inspected.
To check your vehicle’s eligibility for repair under this or any other recall/service campaign, please click on
the Look Up Recalls link at www.vw.com and enter your Vehicle Identification Number (VIN) into the
Recall/Service Campaign Lookup tool.
If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to
the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and
mail it to us so we can update our records.
20Y6 USA_INTERIM
IMPORTANT SAFETY RECALL
If you should have any questions about this communication, please don’t hesitate to contact Customer
CARE, Monday through Friday from 8AM to 10PM EST and Saturday from 9AM to 5PM EST by phone at
800-893-5298. You are also welcome to e-mail or chat through the “Contact Us” page
http://www.vw.com/contact/.
If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway
Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free
Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
We apologize for any inconvenience this matter may cause; however we are taking this action to help
ensure your safety and continued satisfaction with your vehicle.
Sincerely,
Volkswagen Customer Protection

**************************************************************************************************************

The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 1 of 34
Safety Recall
Code: 20Y6
REVISION
Subject
Suction Pump
Release Date
December 21, 2016
Revision Summary
Certain work instruction steps have been modified to help technicians avoid consequential damage during this repair.
Affected Vehicles
U.S.A. & CANADA: 2015-2016 MY Volkswagen Golf, GTI & Golf SportWagen
Check Campaigns/Actions screen in Elsa on the day of repair to verify that a VIN qualifies for repair under this action. Elsa is the only valid campaign inquiry & verification source.
 Campaign status must show “open.”
 If Elsa shows other open action(s), inform your customer so that the work can also be completed at the same time the vehicle is in the workshop for this campaign.
Problem Description
The suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may have been damaged during assembly. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, may result in a fire.
Corrective Action
Replace the suction pump inside the fuel tank.
Precautions
If a fuel smell is detected in the vehicle, customers should immediately contact an authorized Volkswagen dealer to have the vehicle inspected.
Additionally, customers may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this happens, customers should immediately contact an authorized Volkswagen dealer to have the vehicle inspected.
Parts Information
Parts will be allocated prior to owner notification.
• Targeted allocation will be used for 5Q0201029 (suction pump).
• Upper order limits will be used for 1J0919133B (seal). If your dealership is at the weekly Upper Order Limit, submit requests for additional parts via email to vwoaupperorderlimits@vw.com.
Code Visibility
On or about October 13, 2016, affected vehicles were listed on the Inventory Vehicle Open Campaign Action report under My Dealership Reports (found on www.vwhub.com& OMD Web). A list was not posted for dealers who did not have any affected vehicles.
On or about October 13, 2016, this campaign code showed open on affected vehicles in Elsa.
On or about October 13, 2016, affected vehicles were identified with this campaign code in the VIN Lookup tool at www.vw.com and on the NHTSA VIN lookup tool at www.safercar.gov.
Owner Notification
Owner notification will took place in October. Owner letter examples are included in this bulletin for your reference.
Additional Information
Please alert everyone in your dealership about this action, including Sales, Service, Parts and Accounting personnel. Contact Warranty if you have any questions.
The information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These procedures
are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To determine whether
this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 2 of 34
IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their inventory which are involved in a safety or compliance recall until the defect has been remedied.
Dealers must ensure that every affected inventory vehicle has this campaign completed before delivery to consumers.
Fill out and affix Campaign Completion Label (CAMP 010 000) after work is complete.
Labels can be ordered at no cost via the Compliance Label Ordering portal at www.vwhub.com.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 3 of 34
Claim Entry Instructions
After campaign has been completed, enter claim as soon as possible to help prevent work from being duplicated elsewhere. Attach the Elsa screen print showing action open on the day of repair to the repair order.
If customer refused campaign work:
 U.S. dealers: Submit request via WISE under the Campaigns/Update/Recall Closure option.
 Canada dealers: Fax repair order to Warranty at (905) 428-4811.
Service Number
20Y6
Damage Code
0099
Parts Vendor Code
WWO
Claim Type
Sold vehicle: 7 10
Unsold vehicle: 7 90
Causal Indicator
Mark suction pump as causal part*
Vehicle Wash/Loaner
Do not claim wash/loaner under this action
Criteria I.D.
01
Replace Suction Pump.
Labor operation: 2066 23 99 110 T.U.
Quantity
Part Number
Description
1
5Q0201029
Suction Pump*
1
1J0919133B
Seal
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 4 of 34
Customer Letter Example (USA) – INTERIM

This notice applies to your vehicle:
NHTSA: 16V647
IMPORTANT!
Information about Safety Recall 20Y6 – Suction Pump
Your vehicle is affected by the safety recall described in this letter; however, due to limited parts supply, your dealer may not be able to perform the recall work for you at this time. In the interim, if you have any concerns about driving your vehicle, or if you smell fuel in the vehicle, make an appointment with your authorized Volkswagen dealer to have the vehicle inspected/repaired without delay.
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show you are the owner of a vehicle affected by this recall.
Recall Description: On certain vehicles, the suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may have been damaged during assembly. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Precautions You Should Take: If you smell fuel in the vehicle, make an appointment with your authorized Volkswagen dealer to have the vehicle inspected without delay.
Additionally, you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this happens, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
To check your vehicle’s eligibility for repair under this or any other recall/service campaign, please click on the Look Up Recalls link at www.vw.com and enter your Vehicle Identification Number (VIN) into the Recall/Service Campaign Lookup tool.
If you should have any questions about this communication, please don’t hesitate to contact Customer CARE, Monday through Friday from 8AM to 10PM EST and Saturday from 9AM to 5PM EST by phone at 800-893-5298. You are also welcome to e-mail or chat through the “Contact Us” page http://www.vw.com/contact/.
If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle.
Sincerely,
Volkswagen Customer Protection
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 5 of 34
Customer Letter Example (USA) – LAUNCH
This notice applies to your vehicle:
NHTSA:
Subject: Safety Recall 20Y5 – Suction Pump
Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen Vehicles
Dear Volkswagen Owner,
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show that you are the owner of a vehicle affected by this action.
What is the issue?
The suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may have been damaged during assembly. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, may result in a fire.
What will we do?
To help correct this defect, your authorized Volkswagen dealer will replace the suction pump inside the fuel tank. This work will take less than two hours to complete and will be performed for you free of charge. What should you do?
Please contact your authorized Volkswagen dealer without delay to schedule this recall repair. For your convenience, you can also visit www.vw.com and click on the “Owners” link to locate a dealer near you and schedule this service online.
Precautions you should take
If you smell fuel in the vehicle, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
Additionally, you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this happens, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
Lease vehicles and address changes
If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and mail it to us so we can update our records.
Reimbursement of Expenses
If you have previously paid for repairs relating to the condition described in this letter, please refer to the enclosed form that explains how to request reimbursement.
Can we assist you further?
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable time, or if you should have any questions about this communication, please reach out to us using your preferred method of communication at www.vw.com/contact or by calling 1 800-893-5298. Our phone team is available Monday through Friday from 8AM to 10PM EST and Saturday from 9AM to 5PM EST.
Checking your vehicle for open Recalls and Service Campaigns
To check your vehicle’s eligibility for repair under this or any other recall/service campaign, please click on the Look Up Recalls link at www.vw.com and enter your Vehicle Identification Number (VIN) into the Recall/Service Campaign Lookup tool.
If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov.
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Customer Protection
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 6 of 34
Customer Letter Example (CANADA) – INTERIM

This notice applies to your vehicle:
IMPORTANT!
Information about Safety Recall 20Y6 – Suction Pump
Your vehicle is affected by the safety recall described in this letter; however, due to limited parts supply, your dealer may not be able to perform the recall work for you at this time. In the interim, if you have any concerns about driving your vehicle, or if you smell fuel in the vehicle, make an appointment with your authorized Volkswagen dealer to have the vehicle inspected/repaired without delay.
This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show you are the owner of a vehicle affected by this recall.
Recall Description: On certain vehicles, the suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may have been damaged during assembly. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, could lead to a fire causing injury and/or damage to property.
Precautions You Should Take: If you smell fuel in the vehicle, make an appointment with your authorized Volkswagen dealer to have the vehicle inspected without delay.
Additionally, you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this happens, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
If you should have any questions about this communication, please contact Customer Relations, Monday through Friday from 8AM to 8PM EST by phone at 1-800-822-8987 or via our “Contact Us” page at www.vw.ca.
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle.
Sincerely,
Volkswagen Customer Protection
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 7 of 34
Customer Letter Example (CANADA) – LAUNCH

This notice applies to your vehicle:
Subject: Safety Recall 20Y5 – Suction Pump
Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen Vehicles
Dear Volkswagen Owner,
This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act. Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show that you are the owner of a vehicle affected by this action.
What is the issue?
The suction pump inside the fuel tank designed to purge fuel from the evaporative emissions (EVAP) system may have been damaged during assembly. This could cause fuel to flow directly into the EVAP system which could, over time, accumulate and cause a leak through the charcoal canister filter element. Leaking fuel, in the presence of an ignition source, may result in a fire.
What will we do?
To help correct this defect, your authorized Volkswagen dealer will replace the suction pump inside the fuel tank. This work will take less than two hours to complete and will be performed for you free of charge.
What should you do?
Please contact your authorized Volkswagen dealer without delay to schedule this recall repair.
Precautions you should take
If you smell fuel in the vehicle, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
Additionally, you may experience refueling issues (early stopping of the fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this happens, immediately contact the nearest authorized Volkswagen dealer to have the vehicle inspected.
Lease vehicles and address changes
If you are the lessor and registered owner of the vehicle identified in this action, the law requires you to forward this letter immediately via first-class mail to the lessee within ten (10) days of receipt. If you have changed your address or sold the vehicle, please fill out the enclosed prepaid Owner Reply card and mail it to us so we can update our records.
Reimbursement of Expenses
If you have previously paid for repairs relating to the condition described in this letter, please refer to the enclosed form that explains how to request reimbursement.
Can we assist you further?
If your authorized Volkswagen dealer fails or is unable to complete this work free of charge within a reasonable time, please contact Customer Relations, Monday through Friday from 8AM to 8PM EST by phone at 1-800-822-8987 or via our “Contact Us” page at www.vw.ca.
We apologize for any inconvenience this matter may cause; however we are taking this action to help ensure your safety and continued satisfaction with your vehicle. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Customer Protection
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 8 of 34
Campaign Work Procedure 20Y6 Safety Recall
NOTE
Damages resulting from improper repair or failure to follow these work instructions are the dealer’s responsibility and are not eligible for reimbursement under this action.
Required Parts
Quantity
Part Number
Part Description
1
5Q0-201-029
Suction Pump
1
1J0-919-133-B
Seal
Required Tools
• Wrench – Fuel Sending Unit -T10202-
• Torque Wrench 1332 40-200Nm -VAG1332- (or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 9 of 34
• Trim Removal Wedge -3409-
• VAS6150D – Diagnostic Tester (or equivalent)
• VAS6154 – Vehicle Communication Interface (or equivalent)
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 10 of 34
• GRX3000VAS – Battery Tester/Charger (or equivalent)
• Fuel Extractor VAS5190A -VAS5190-.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 11 of 34
Repair Instruction
Section A – Check for Previous Repair
TIP
If Campaign Completion label is present, no further work is required.
• Enter the VIN in Elsa and proceed to the “Campaign/Action” screen.
TIP
On the date of repair, print this screen and keep a copy with the repair order.
• Confirm the Campaign/Action is open . If the status is closed, no further work is required.
• Note the Applicable Criteria ID for use in determining the correct work to be done and corresponding parts associated.
Proceed to Section B
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 12 of 34
Section B – Repair Procedure
NOTE
• Due to variations in vehicle equipment and options, the steps/illustrations in this work procedure may not identically match all affected vehicles.
• This procedure must be read in its entirety before performing the repair.
NOTE
Follow these “rules” when working on the fuel supply system:
• Thoroughly clean the connecting points and the surrounding area before loosening.
• Place the removed parts on a clean surface and cover them. Only use lint-free cloths!
• Carefully cover or seal opened components if the repair will not be done immediately.
• Only install clean parts: remove replacement parts from the packaging immediately prior to installation. Do not use parts that have been stored loose (for example, in tool boxes etc.).
• When the system is open: do not work with compressed air.
• Do not move vehicle.
• Seal off any open lines and connections immediately with plugs, for example, take from -VAS6122-.
• Protect the disconnected connectors from dirt and moisture and only connect when they are dry.
• Before starting work, place the extracting hose on an exhaust extractor that is switched on near the fuel tank assembly opening to extract fuel vapors.
WARNING
Risk for repeat repair!
It is imperative that the battery is disconnected before draining the fuel. Failing to disconnect the battery can result in fuel level sending unit faults, or fuel gauge inaccuracies. Additional diagnostic time required to perform a capacitive discharge or remove fused power to the instrument cluster to clear these faults or inaccuracies are NOT covered under this campaign.
• Move the front seats all the way forward.
o On vehicles equipped with power seats, be sure to move the front seats all the way forward before disconnecting the battery in the next step.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 13 of 34
• Open the vehicle hood.
• Open the battery heat protection sleeve cover to access the cover <1> on the battery ground terminal <2>.
• Loosen the nut <3> several turns and remove the battery ground terminal <2> from the negative battery post and isolate the terminal.
• Unclip and remove the covers <1> from the LATCH child seat anchors .
CAUTION
Edges on the child seat anchor cover may be sharp.
• Push the guides <1>, corresponding to cut-out, downward and disengage them from the LATCH child seat anchors <2>.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 14 of 34
• With both hands, grasp the rear bench seat under the seat frame.
• Pull the rear bench seat <1> up forcefully with both hands so the wire hooks <2> on the rear bench seat release from the mounting grommet <3>.
• Repeat the procedure on the other side of the rear bench seat .
• Gently lift the rear bench seat <1> at front and slide the wire frame <2> out of the hook <3> toward the rear.
• Remove the rear bench seat from the vehicle.
NOTE
Place the seat bench in a clean location where it will not be damaged. Damage to the seat bench is not covered under this action.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 15 of 34
WARNING
Risk for repeat repair!
It is imperative that the exact amount of fuel removed from the fuel tank is reinstalled into the fuel tank at the end of this operation. Failing to reinstall the same of amount of fuel that was extracted can result in fuel level sending unit faults, or fuel gauge inaccuracies. Additional diagnostic time required to perform a capacitive discharge or remove fused power to the instrument cluster to clear these faults or inaccuracies are NOT covered under this campaign.
CAUTION
Danger due to escaping fuel.
• Drain the fuel tank.
o If fuel tank is more than ¾ full, proceed to subsection 1.
o If fuel tank is less than ¾ full, proceed to subsection 2.
Subsection 1 – Fuel Tank More Than ¾ Full
NOTE
Use only the Fuel Extractor Unit -VAS5190A- when extracting E 85 – fuel!
• Use insulating tape to mark the hose at the distance from the end of the suction hose on the -VAS5190-.
Rear Axle
Distance of
Multi-link
945 mm
Torsion Beam Rear Suspension
1010 mm
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 16 of 34
• Open the fuel filler door unit.
• Clean the area around the fuel filler neck<2>.
• Remove the cap <1> for the fuel filler neck.
• Attach the ground wire from the -VAS5190A- to a bare area on the body.
• Slide the suction hose from the -VAS5190A- into the fuel tank until the previously made mark -arrow- meets the filler neck <2>.
• Drain the fuel tank as much as possible through the filler neck.
NOTE
• A valve <1> is located in the fuel tank on the lower end of the filler neck. It must not be damaged by the suction hose. Only slide the hose in as far as the mark that was made earlier .
• When no more fuel can be extracted, the fuel tank has been emptied enough so that the sensor flange can be opened safely.
• Carefully remove the suction hose.
NOTE
Do not use force to remove the suction hose if it gets stuck on the check valve. In this case, remove the fuel delivery unit and manually hold the check valve open. When doing this, make sure the arm does not come in contact with the fuel.
Proceed to Subsection 2.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 17 of 34
Subsection 2 – Fuel Tank Less Than ¾ Full
WARNING
• The fuel system is under high pressure.
• Risk of injury from fuel spraying out.
• Reduce the pressure before continuing procedure.
Risk of a fire due to leaking fuel.
• When the battery is connected, the door contact switch activates the fuel pump when opening the driver door. Leaking fuel can ignite and start a fire.
• Before opening the fuel system, interrupt the power supply to the fuel pump.
• In the rear seat, unclip the sealing flange cover <1> at the tabs using the Trim Removal Wedge -3409-.
• Unclip the grommet <1> downward out of the cover <2>.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 18 of 34
• Prior to disassembly, the fuel delivery unit MUST be clean. If excessive dirt or debris is present , clean and dry the fuel delivery unit and surrounding areas as necessary.
• Unlock and disconnect the connector <1> from the sealing flange.
• If equipped, disengage the connector <2> for the parking heater Metering Pump -V54- on the sealing flange and move it to the side.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 19 of 34
WARNING
Fuel lines are under pressure. Danger of personal injury to eyes and skin. Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Open the connection carefully and release the pressure.
• Remove the fuel line connector <1> from the locking flange by pushing down on the connector, squeezing the release tab between the finger and thumb, then lifting up.
• If equipped, remove the fuel line <2> to the Metering Pump -V54- for the parking heater on the sealing flange by loosening the lower hose clamp.
NOTE
Risk for repeat repair!
• Do not use pliers or other tools on the fuel line connector(s) or damage to the connector may occur.
• Damage to the fuel line connector due to improper removal/installation may cause the connector to not fasten securely upon reinstallation, causing a leak. A damaged fuel line connector requires replacement of the fuel line.
• Consequential damage to the fuel line connector(s) due to improper removal/installation is not covered under this campaign.
• Remove the locking ring using the Wrench – Fuel Sending Unit -T10202-.
• Carefully lift the fuel delivery unit flange.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 20 of 34
• Pull the sealing flange <2> out of the opening in the fuel tank slightly.
• Remove the seal <1> and slightly lift the fuel delivery unit flange again carefully.
NOTE
Use only the Fuel Extractor Unit -VAS5190A- when extracting E 85 – fuel!
• Attach the ground wire of the -VAS5190- to a bare area on the body.
• Insert the suction hose for the -VAS5190- as deep as possible into the fuel tank.
• Extract the fuel using the -VAS5190.
• Insert the extraction hose into the fuel delivery unit.
• Drain as much fuel as possible from the fuel delivery unit itself.
• Record the total amount of fuel extracted using the -VAS 5190- Fuel Extraction Unit on the repair order.
WARNING
Risk for repeat repair!
• It is imperative that the exact amount of fuel removed from the fuel tank is reinstalled into the fuel tank at the end of this operation.
• Failing to reinstall the same of amount of fuel that was extracted can result in fuel level sending unit faults, or fuel gauge inaccuracies.
• Additional diagnostic time required to perform a capacitive discharge or remove fused power to the instrument cluster to clear these faults or inaccuracies are NOT covered under this campaign.
• Once the fuel has been properly evacuated, carefully pull the fuel delivery unit with the fuel level sensor out through the opening in the fuel tank, using caution not to bend the floater arm on the fuel level sensor when removing.
CAUTION
Risk for repeat repair!
During removal of the fuel delivery unit, it is very easy to damage the fuel level sensor. Use caution when removing the fuel delivery unit. Damage to the fuel level sensor is not covered under this action.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 21 of 34
• Place a cloth underneath to catch the residual fuel, since the fuel delivery unit may still be partially filled.
• Carefully pull the fuel delivery unit <2> out of the fuel tank, release the fuel line <1> and disconnect it from the front suction line <3>.
• Lay a cloth inside the vehicle to absorb any residual fuel.
NOTE
• Follow all waste disposal regulations.
• Check the fuel tank for contamination.
NOTE
Risk for repeat repair!
• Do not use pliers or other tools on the fuel line connector <1> or damage to the connector may occur.
• Damage to the fuel line connector due to improper removal/installation may cause the connector to not fasten securely upon reinstallation, causing a leak. A damaged fuel line connector on the suction pump line requires replacement of the FUEL TANK.
• Consequential damage to the fuel tank due to connector damage from improper removal/installation is not covered under this campaign.
• After the fuel delivery unit is removed from the fuel tank opening and the suction pump line is disconnected, insert the suction hose from the -VAS 5910- Fuel Extraction Unit to remove as much additional fuel as necessary to perform the remaining operations safeley and comfortably.
• Add any additional fuel removed from the fuel delivery unit and/or the bottom of the tank to the fuel volume previously recorded on the repair order.
WARNING
Danger due to fuel contacting skin
• To prevent injury or discomfort, wear proper protective gear when skin may come in contact with fuel. Proper fuel resistant gloves are advised.
• Take care when working on a vehicle that has been stored outdoors in extreme climate conditions. Fuel will not freeze when exposed to extreme cold, therefore the fuel in the tank may be well below 0°C.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 22 of 34
Use cold weather protective gear or equipment as necessary, drain all of the fuel out, or warm the vehicle indoors if the vehicle has been stored in an extreme climate condition before performing the next steps.
NOTE
• Check the fuel tank for contamination and if any is noted use the VAS 5190 Fuel Extraction Unit to vacuum any debris from the tank. If necessary, use a lint free cloth to remove any debris once all fuel has been removed.
Replacing the suction jet pump:
TIP
• To view a short video overview on removing and reinstalling the suction pump, scan the QR code to the left.
• The QR code is for viewing the video on smartphones and tablets. Alternatively, the video can also be accessed through computer internet browsers with the link below:
https://youtu.be/O1H7_8IRTVI
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 23 of 34
NOTE
• The fuel tank in the illustration below has been sectioned to provide a clear view of the suction valve.
• Under no circumstances should the fuel tank be altered or modified as shown below.
• Reach into the fuel tank and follow the black hose to find the suction pump <1>.
• Disconnect the rear suction line <2>:
o Push the connector further onto the suction pump.
o Press and hold the quick release connector latch in with the thumb.
o Pull the connector off (downward).
NOTE
Risk for repeat repair!
• Do not use pliers or other tools on the fuel line connector <2 and 3> or damage to the connector may occur.
• Damage to the fuel line connector(s) due to improper removal/installation may cause the connector to not fasten securely upon reinstallation, causing a leak. A damaged fuel line connector on the front or rear suction pump line requires replacement of the FUEL TANK.
• Consequential damage to the fuel tank due to connector damage from improper removal/installation is not covered under this campaign.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 24 of 34
• Remove the suction pump <1> off the retainer bracket <3>:
o Slightly rotate suction pump <1> away from the bracket <3>
o Remove the pump <1> from the fuel tank by gently rocking it back and forth between the fingers and thumb.
o Use caution not to damage the attached front suction line.
• Take care that the Liquid-Vapor Separator Assembly <1> does not come off of its attachment bracket when removing the Suction Jet Pump.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 25 of 34
NOTE
Risk for repeat repair!
• If the Liquid-Vapor Separator <1> comes loose and is not reinstalled onto the mounting bracket, a customer comeback for rattling in the fuel tank, or EVAP system faults may occur.
• The Liquid-Vapor Separator <1> can be reinstalled onto its mounting bracket <2>.
• Replacement of the fuel tank for the Liquid-Vapor Separator dislodging from the mounting bracket are not covered under this campaign.
• If the Liquid-Vapor Separator Assembly <1> comes off the mounting bracket during suction pump removal:
o Snap the Liquid-Vapor Separator <1> back into place by realigning it with the mounting bracket.
o Push down on the Liquid-Vapor Seperator to reengage the clip <2>.
• When correctly installed, the Liquid-Vapor Separator clip will be secured into its mounting bracket as shown.
NOTE
• The fuel tank does NOT require replacement if the Liquid-Vapor Separator Assembly is dislodged from its mounting bracket during removal of the Suction Jet Pump.
• Consequential damage for fuel tank replacement is not covered under this campaign for dislodged Liquid-Vapor Separator Assemblies.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 26 of 34
• Disconnect the front suction line <1> from the suction pump:
o Push the front suction line <1> further onto the suction pump <2>.
o Press the release <3> with the thumb, then pull the front suction line <3> off of the suction pump <2>.
• Transfer the front suction line <1> from the old suction pump <2> to the new suction pump, ensuring that the locking of the retention clip <3> is felt and/or heard.
TIP
• The red colored connector <3> on the front suction line connects to the suction pump.
• The green colored connector on the front suction line connects to the fuel delivery unit.
NOTE
Risk for repeat repair!
• Do not use pliers or other tools on the fuel line connector <3> or damage to the connector may occur.
• Damage to the fuel line connector due to improper removal/installation may cause the connector to not fasten securely upon reinstallation, causing a leak. A damaged fuel line connector on the suction pump line requires replacement of the FUEL TANK.
• Consequential damage to the fuel tank due to connector damage from improper removal/installation is not covered under this campaign.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 27 of 34
• Insert the new suction pump <1> into the fuel tank.
• Align the retention clip on the new suction pump <1> to the bracket <2> on the liquid-vapor seperator.
• Slide the new suction pump <1> downward onto the bracket <2>.
• Ensure that the pump is secured firmly on the bracket <2>.
Part Number
Part Description
5Q0-201-029
Suction Pump
NOTE
Use caution not to damage the attached front suction line during installation.
• Reconnect the rear suction line <2> to the suction pump <1>, ensuring that the locking of the retention clip is felt and/or heard.
• Ensure that the front suction line <3> and rear suction line <2> are firmly seated and secure by gently pulling the lines away from the suction pump.
NOTE
Risk for repeat repair!
• Do not use pliers or other tools on the fuel line connectors <2 and 3> or damage to the connector may occur.
• Damage to the fuel line connector(s) due to improper removal/installation may cause the connector to not fasten securely upon reinstallation, causing a leak. A damaged fuel line connector on the front or rear suction pump line requires replacement of the FUEL TANK.
• Consequential damage to the fuel tank due to connector damage from improper removal/installation is not covered under this campaign.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 28 of 34
NOTE
When reconnecting fuel lines, ensure that the locking of the retention clip is felt and/or heard.
• Carefully align the fuel delivery unit <2> to the fuel tank and reconnect the fuel line <1> to the front suction line <3>.
• Carefully guide the fuel delivery unit with the fuel level sensor through the opening into the fuel tank.
CAUTION
Risk for repeat repair!
• Be careful not to bend the fuel level sensor when installing the fuel delivery unit.
• Consequential damage to the fuel level sensor is not covered under this campaign.
• Carefully install the dry fuel delivery unit seal <1> into the opening in the fuel tank.
Part Number
Part Description
1J0-919-133-B
Seal
NOTE
The fuel delivery unit seal must be installed dry.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 29 of 34
NOTE
When inserting the sealing flange, the seal must not be damaged or crushed.
• Push the sealing flange <2> down against the spring force.
• Bring the sealing flange into its installation position.
• The arrow <3> on the fuel tank must point to the mark <2> on the sealing flange <1>.
• Using the -T10202-, tighten the locking ring to 110 Nm.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 30 of 34
• Attach the fuel line <1> to the sealing flange until it clicks into place.
• If equipped, install the fuel line <2> to the Metering Pump -V54- for the parking heater on the sealing flange.
• Connect the connector <1>.
• If equipped, engage the connector <2> for the parking heater Metering Pump -V54- on the sealing flange.
• Gently pull on the connectors to make sure they are secure.
• Reattach the grommet <1> into the cover <2>.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 31 of 34
• Reattach the sealing flange cover <1>.
• Prior to reinstalling the rear seat, remove the grommets <1> and check the body openings for deformations.
o If deformation is found, readjust the panel with a plastic hammer.
• Lift the carpet <2> and press in the mounting grommets <1> until they engage audibly in body opening .
• Ensure the carpet does not cover the grommet.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 32 of 34
• Check if the wire frame is aligned in the marked area before installing the rear bench seat.
• If the wire frame is bent, bend it back far enough until it is realigned.
• Install the rear bench seat and push the wire hooks <1> into the mounting grommets <2>.
• Reinstall the guides <1> to the LATCH child seat anchors <2>.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 33 of 34
• Reinstall the covers <1> to the LATCH child seat anchors.
CAUTION
Edges on the child seat anchor cover may be sharp.
• Open the fuel door and remove the fuel cap <2>.
• Refill the fuel tank with the same amount of fuel removed prior with the -VAS 5190- Fuel Extraction Unit.
• Verify using the sightglass on the side of the -VAS 5190- Fuel Extraction Unit that the fuel tank was filled with the same amount of fuel that was extracted before reconnecting the battery.
NOTE
Risk for repeat repair!
Failing to fill the fuel tank with the same of amount of fuel that was extracted can result in fuel level sending unit faults, or fuel gauge inaccuracies. Additional diagnostic time required to perform a capacitive discharge or remove fused power to the instrument cluster to clear these faults or inaccuracies are NOT covered under this campaign.
The repair information in this document is intended for use only by skilled technicians who have the proper tools, equipment and training to correctly and safely maintain your vehicle. These
procedures are not intended to be attempted by “do-it-yourselfers,” and you should not assume this document applies to your vehicle, or that your vehicle has the condition described. To
determine whether this information applies, contact an authorized Volkswagen dealer. 2016 Volkswagen Group of America, Inc. and Volkswagen Canada. All Rights Reserved.
December 2016 20Y6 Page 34 of 34
• Deisolate and then reconnect the negative battery terminal <2> to the battery post.
• Tighten the nut <3> to 6 Nm.
• Switch the ignition ON.
• Attach an appropriate VAS tester to the vehicle.
• Clear all DTCs.
• Cycle the ignition multiple times and check for fuel leaks.
• Reset customer convenience basic settings (i.e. one touch windows, instrument cluster clock, etc.).
Proceed to section C.
Section C – Campaign Completion Label
Install Campaign Completion Label
• Fill out and affix Campaign Completion Label, part number CAMP 010 000, next to the vehicle emission control information label.
TIP
Ensure Campaign Completion Label does not cover any existing label(s).
• Proceed to Section D.
Section D – Parts Return/Disposal
Properly store (retain), destroy or dispose of removed parts in accordance with all state/province and local requirements, unless otherwise indicated and/or requested through the Warranty Parts Portal (WPP).

**************************************************************************************************************

20Y6 USA
IMPORTANT SAFETY RECALL
Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326

This notice applies to your vehicle:
NHTSA: 16V647
Subject: Safety Recall 20Y6 – Suction Pump
Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen Vehicles
Dear Volkswagen Owner,
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-
2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show that you are
the owner of a vehicle affected by this action.
What is the issue? The suction pump inside the fuel tank designed to purge fuel from the
evaporative emissions (EVAP) system may have been damaged during
assembly. This could cause fuel to flow directly into the EVAP system which
could, over time, accumulate and cause a leak through the charcoal
canister filter element. Leaking fuel, in the presence of an ignition source,
may result in a fire.
What will we do? To help correct this defect, your authorized Volkswagen dealer will replace
the suction pump inside the fuel tank. This work will take less than two
hours to complete and will be performed for you free of charge.
What should you do? Please contact your authorized Volkswagen dealer without delay to
schedule this recall repair. For your convenience, you can also visit
www.vw.com and click on the “Owners” link to locate a dealer near you and
schedule this service online.
Precautions you should
take
If you smell fuel in the vehicle, immediately contact the nearest authorized
Volkswagen dealer to have the vehicle inspected.
Additionally, you may experience refueling issues (early stopping of the fuel
nozzle and fuel spillback) when fuel accumulates in the EVAP system. If
this happens, immediately contact the nearest authorized Volkswagen
dealer to have the vehicle inspected.
20Y6 USA
IMPORTANT SAFETY RECALL
Lease vehicles and
address changes
If you are the lessor and registered owner of the vehicle identified in this
action, the law requires you to forward this letter immediately via first-class
mail to the lessee within ten (10) days of receipt. If you have changed your
address or sold the vehicle, please fill out the enclosed prepaid Owner
Reply card and mail it to us so we can update our records.
Reimbursement of
Expenses
If you have previously paid for repairs relating to the condition described in
this letter, please refer to the enclosed form that explains how to request
reimbursement.
Can we assist you
further?
If your authorized Volkswagen dealer fails or is unable to complete this work
free of charge within a reasonable time, or if you should have any questions
about this communication, please reach out to us using your preferred
method of communication at www.vw.com/contact or by calling 1 800-893-
5298. Our phone team is available Monday through Friday from 8AM to
10PM EST and Saturday from 9AM to 5PM EST.
Checking your vehicle
for open Recalls and
Service Campaigns
To check your vehicle’s eligibility for repair under this or any other
recall/service campaign, please click on the Look Up Recalls link at
www.vw.com and enter your Vehicle Identification Number (VIN) into the
Recall/Service Campaign Lookup tool.
If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call
the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
We apologize for any inconvenience this matter may cause; however we are taking this action to help
ensure your safety and continued satisfaction with your vehicle. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Customer Protection
20Y6 USA
IMPORTANTE RETIRO DEL MERCADO POR MOTIVOS DE SEGURIDAD
Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326

<DIRECCIÓN DEL CLIENTE>

Este aviso corresponde a su vehículo: <NÚMERO DE IDENTIFICACIÓN DEL VEHÍCULO>
NHTSA: 16V647
Asunto: Retiro del mercado por motivos de seguridad 20Y5 – Bomba de aspiración
Determinados vehículos Volkswagen Golf, GTI y Golf SportWagen modelos 2015 y 2016
Estimado(a) propietario(a) de un vehículo Volkswagen:
Se le envía este aviso de acuerdo con los requisitos de la Ley Nacional de Seguridad de Tráfico y
Vehículos Motorizados (National Traffic and Motor Vehicle Safety Act). Volkswagen ha determinado
que existe un defecto relacionado con la seguridad vehicular en algunos vehículos Volkswagen Golf,
GTI y Golf SportWagen modelos 2015 y 2016. Nuestros registros indican que usted es propietario(a)
de uno de los vehículos afectados por esta medida.
¿Cuál es el
inconveniente?
Es posible que la bomba de aspiración interna del tanque de combustible
diseñada para eliminar el combustible del sistema de evaporación de
emisiones (EVAP) se haya dañado durante el montaje. Esto podría
ocasionar un derrame de combustible directamente en el sistema EVAP
que, con el transcurso del tiempo, podría acumularse y producir pérdidas a
través del material filtrante del recipiente de carbón. Dicha fuga podría
ocasionar un incendio ante la presencia de una fuente de ignición.
¿Qué haremos? Para poder corregir este defecto, su concesionario Volkswagen autorizado
reemplazará la bomba de aspiración interna del tanque de combustible de
su vehículo. Este servicio se realizará en menos de dos horas y de forma
gratuita.
¿Qué debe hacer
usted?
Comuníquese con su concesionario Volkswagen autorizado de inmediato
para programar este servicio de reparación. Para su comodidad, también
puede visitar www.vw.com y hacer clic en el enlace “Propietarios” para
ubicar a un concesionario cercano a su domicilio y programar este servicio
en línea.
Precauciones que debe
tomar
Si detecta olor a combustible en el vehículo, comuníquese con el
concesionario Volkswagen autorizado más cercano a su domicilio para que
su vehículo sea revisado cuanto antes.
20Y6 USA
IMPORTANTE RETIRO DEL MERCADO POR MOTIVOS DE SEGURIDAD
Incluso, puede tener problemas a la hora de cargar combustible (detención
prematura de la boquilla de combustible y retorno de combustible) cuando
el combustible se acumula en el sistema EVAP. Si esto sucede,
comuníquese de inmediato con su concesionario Volkswagen autorizado
para que se inspeccione el vehículo.
Vehículos arrendados y
cambios de dirección
Si usted es el arrendador y propietario registrado del vehículo identificado
en esta campaña, la ley exige que reenvíe esta carta de inmediato al
arrendatario por correo de primera clase en el plazo de diez (10) días a
partir de su recepción. Si cambió su dirección o vendió el vehículo,
complete la tarjeta prepaga de Respuesta del propietario que se encuentra
adjunta y envíela por correo para que podamos actualizar sus datos en
nuestros registros.
Reembolso de gastos Si pagó anteriormente por reparaciones relacionadas con el problema que
se describe en esta carta, consulte el formulario adjunto que explica cómo
presentar una solicitud de reembolso.
¿Necesita más ayuda? Si su concesionario Volkswagen autorizado no puede o no está en
condiciones de prestar este servicio gratuito dentro de un plazo razonable,
o si tiene alguna pregunta sobre esta notificación, comuníquese con
nosotros a través de www.vw.com/contact o por teléfono al 1-800-893-
5298. Nuestros operadores telefónicos están disponibles de lunes a viernes
de 8 a. m. a 10 p. m., y los días sábados de 9 a. m. a 5 p. m., hora estándar
del este.
Comprobación de la
elegibilidad de su
vehículo para
campañas de servicio y
retiros del mercado
Si desea comprobar la elegibilidad de su vehículo para una reparación en
virtud de esta u otras campañas de servicio/retiro del mercado, haga clic en
el enlace Look Up Recalls (Búsqueda de retiros del mercado) en
www.vw.com e ingrese su número de identificación del vehículo (VIN) en la
herramienta Recall/Service Campaign Lookup(Búsqueda de campaña de
servicio/retiro del mercado).
Si aún no está satisfecho, puede presentar una queja a la siguiente dirección: The Administrator,
National Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC
20590. También puede llamar a la línea directa gratuita de seguridad vehicular, al +1 888 327-4236
(TTY: +1 800 424-9153) o visitar la página http://www.safercar.gov.
Le pedimos disculpas por cualquier inconveniente que esto pueda haberle ocasionado; no obstante,
hemos tomado medidas para garantizar su seguridad y su continua satisfacción con el vehículo.
Muchas gracias por conducir un Volkswagen.
Atentamente.
Defensa del Consumidor de Volkswagen

**************************************************************************************************************

20Y6 USA
IMPORTANT SAFETY RECALL
Volkswagen of America, Inc.
3800 Hamlin Road
Auburn Hills, MI 48326

This notice applies to your vehicle:
NHTSA: 16V647
Subject: Safety Recall 20Y6 – Suction Pump
Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen Vehicles
Dear Volkswagen Owner,
This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.
Volkswagen has decided that a defect, which relates to motor vehicle safety, exists in certain 2015-
2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles. Our records show that you are
the owner of a vehicle affected by this action.
What is the issue? The suction pump inside the fuel tank designed to purge fuel from the
evaporative emissions (EVAP) system may have been damaged during
assembly. This could cause fuel to flow directly into the EVAP system which
could, over time, accumulate and cause a leak through the charcoal
canister filter element. Leaking fuel, in the presence of an ignition source,
may result in a fire.
What will we do? To help correct this defect, your authorized Volkswagen dealer will replace
the suction pump inside the fuel tank. This work will take less than two
hours to complete and will be performed for you free of charge.
What should you do? Please contact your authorized Volkswagen dealer without delay to
schedule this recall repair. For your convenience, you can also visit
www.vw.com and click on the “Owners” link to locate a dealer near you and
schedule this service online.
Precautions you should
take
If you smell fuel in the vehicle, immediately contact the nearest authorized
Volkswagen dealer to have the vehicle inspected.
Additionally, you may experience refueling issues (early stopping of the fuel
nozzle and fuel spillback) when fuel accumulates in the EVAP system. If
this happens, immediately contact the nearest authorized Volkswagen
dealer to have the vehicle inspected.
20Y6 USA
IMPORTANT SAFETY RECALL
Lease vehicles and
address changes
If you are the lessor and registered owner of the vehicle identified in this
action, the law requires you to forward this letter immediately via first-class
mail to the lessee within ten (10) days of receipt. If you have changed your
address or sold the vehicle, please fill out the enclosed prepaid Owner
Reply card and mail it to us so we can update our records.
Reimbursement of
Expenses
If you have previously paid for repairs relating to the condition described in
this letter, please refer to the enclosed form that explains how to request
reimbursement.
Can we assist you
further?
If your authorized Volkswagen dealer fails or is unable to complete this work
free of charge within a reasonable time, or if you should have any questions
about this communication, please reach out to us using your preferred
method of communication at www.vw.com/contact or by calling 1 800-893-
5298. Our phone team is available Monday through Friday from 8AM to
10PM EST and Saturday from 9AM to 5PM EST.
Checking your vehicle
for open Recalls and
Service Campaigns
To check your vehicle’s eligibility for repair under this or any other
recall/service campaign, please click on the Look Up Recalls link at
www.vw.com and enter your Vehicle Identification Number (VIN) into the
Recall/Service Campaign Lookup tool.
If you still cannot obtain satisfaction, you may file a complaint with: The Administrator, National
Highway Traffic Safety Administration, 1200 New Jersey Avenue, SE., Washington, DC 20590; or call
the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153); or go to
http://www.safercar.gov.
We apologize for any inconvenience this matter may cause; however we are taking this action to help
ensure your safety and continued satisfaction with your vehicle. Thank you for driving a Volkswagen!
Sincerely,
Volkswagen Customer Protection

**************************************************************************************************************

20Y6/H0/UPD
VOLKSWAGEN DEALERSHIP COMMUNICATION
Date: October 7, 2016
To: Dealer Principal, Sales Manager, Service Manager, Parts Manager and Warranty Administrator
Subject: Updated: Advance Notice – Safety Recall 20Y6 – Suction Pump
IMPORTANT NOTICE TO DEALERS – FOR IMMEDIATE DISTRIBUTION
Volkswagen has notified NHTSA and Transport Canada about the upcoming safety recall described in this letter.
CODE 20Y6
We anticipate a small parts allocation will take place early next week so that
repairs can begin as soon as possible.
AFFECTED VEHICLES Certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles
RECALL DESCRIPTION The suction pump inside the fuel tank designed to purge fuel from the evaporative
emissions (EVAP) system may have been damaged during assembly. This could
cause fuel to flow directly into the EVAP system which could, over time, accumulate
and cause a leak through the charcoal canister filter element. Leaking fuel, in the
presence of an ignition source, may result in a fire.
PRECAUTIONS If a fuel smell is detected in the vehicle, customers should immediately contact an
authorized Volkswagen dealer to have the vehicle inspected.
Additionally, customers may experience refueling issues (early stopping of the fuel
nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this
happens, customers should immediately contact an authorized Volkswagen dealer
to have the vehicle inspected.
CORRECTIVE ACTION Repair information will be provided to dealers when parts and repair instructions
become available to support this recall.
Dealers will replace the suction pump inside the fuel tank.
IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of Federal law for a dealer to deliver a new motor
vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this
notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must
correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal
Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their
inventory which are involved in a safety or compliance recall until the defect has been remedied.
If you have any questions or require additional assistance, please contact Warranty. As always, any press inquiries
should be directed to Volkswagen Public Relations.
Volkswagen Customer Protection

**************************************************************************************************************

20Y6/H0
VOLKSWAGEN DEALERSHIP COMMUNICATION
Date: October 7, 2016
To: Dealer Principal, Sales Manager, Service Manager, Parts Manager and Warranty Administrator
Subject: Advance Notice – Safety Recall 20Y6 – Suction Pump
IMPORTANT NOTICE TO DEALERS – FOR IMMEDIATE DISTRIBUTION
Volkswagen has notified NHTSA and Transport Canada about the upcoming safety recall described in this letter.
CODE 20Y6
Affected vehicles will be identified in ELSA and VIN lookup with the status REPAIR
NOT YET AVAILABLE shortly.
AFFECTED VEHICLES Certain 2015-2016 model year Volkswagen Golf, GTI & Golf SportWagen vehicles
RECALL DESCRIPTION The suction pump inside the fuel tank designed to purge fuel from the evaporative
emissions (EVAP) system may have been damaged during assembly. This could
cause fuel to flow directly into the EVAP system which could, over time, accumulate
and cause a leak through the charcoal canister filter element. Leaking fuel, in the
presence of an ignition source, may result in a fire.
PRECAUTIONS If a fuel smell is detected in the vehicle, customers should immediately contact an
authorized Volkswagen dealer to have the vehicle inspected.
Additionally, customers may experience refueling issues (early stopping of the fuel
nozzle and fuel spillback) when fuel accumulates in the EVAP system. If this
happens, customers should immediately contact an authorized Volkswagen dealer
to have the vehicle inspected.
CORRECTIVE ACTION Repair information will be provided to dealers when parts and repair instructions
become available to support this recall.
Dealers will replace the suction pump inside the fuel tank.
IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of Federal law for a dealer to deliver a new motor
vehicle or any new or used item of motor vehicle equipment (including a tire) covered by this
notification under a sale or lease until the defect or noncompliance is remedied. By law, dealers must
correct, prior to delivery for sale or lease, any vehicle that fails to comply with an applicable Federal
Motor Vehicle Safety Standard or that contains a defect relating to motor vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned vehicles in their
inventory which are involved in a safety or compliance recall until the defect has been remedied.
If you have any questions or require additional assistance, please contact Warranty. As always, any press inquiries
should be directed to Volkswagen Public Relations.
Volkswagen Customer Protection

**************************************************************************************************************

20Y6
VOLKSWAGEN DEALERSHIP COMMUNICATION
Date: October 12, 2016
To: Dealer Principal, Sales Manager, Service Manager, Parts Manager and Warranty Administrator
Subject: Upcoming Safety Recall 20Y6 – Suction Pump
Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen Vehicles
IMPORTANT NOTICE TO DEALERS – FOR IMMEDIATE DISTRIBUTION
We would like to inform you of an upcoming safety recall. Please refer to the attached Campaign Data
Sheet for additional information.
IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY & COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of Federal law for a dealer to deliver a
new motor vehicle or any new or used item of motor vehicle equipment (including a tire)
covered by this notification under a sale or lease until the defect or noncompliance is
remedied. By law, dealers must correct, prior to delivery for sale or lease, any vehicle that
fails to comply with an applicable Federal Motor Vehicle Safety Standard or that contains a
defect relating to motor vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers should not deliver any pre-owned
vehicles in their inventory which are involved in a safety or compliance recall until the
defect has been remedied.
Dealers must ensure that every affected inventory vehicle has this campaign completed before delivery
to consumers.
If you have any questions or require additional assistance, please contact Warranty. As always, any
press inquiries should be directed to Volkswagen Public Relations.
Volkswagen Customer Protection
Attachment: Campaign Data Sheet (1)
IMPORTANT! To ensure that ALL of your personnel are aware of this action before receiving questions from any customer, please share this information with ALL personnel
who have campaign-related responsibilities, including service writers, technicians, parts employees, warranty administrators, etc. See the campaign circular on Elsa for the
most current repair information. Refer to the campaign circular for complete repair and claiming instructions.
CAMPAIGN DATA SHEET
CAMPAIGN TYPE Safety Recall
SAGA CODE 20Y6
MARKET(S) United States and Canada
AFFECTED VEHICLES Certain 2015-2016 Model Year Volkswagen Golf, GTI & Golf SportWagen
TOPIC Suction Pump
PROBLEM DESCRIPTION The suction pump inside the fuel tank designed to purge fuel from the
evaporative emissions (EVAP) system may have been damaged during
assembly. This could cause fuel to flow directly into the EVAP system which
could, over time, accumulate and cause a leak through the charcoal canister
filter element. Leaking fuel, in the presence of an ignition source, may result
in a fire.
CORRECTIVE ACTION Replace the suction pump inside the fuel tank.
PRECAUTIONS If a fuel smell is detected in the vehicle, customers should immediately contact
an authorized Volkswagen dealer to have the vehicle inspected.
Additionally, customers may experience refueling issues (early stopping of the
fuel nozzle and fuel spillback) when fuel accumulates in the EVAP system. If
this happens, customers should immediately contact an authorized
Volkswagen dealer to have the vehicle inspected.
CUSTOMER NOTIFICATION DATE Beginning October 2016
ELSA/OMD WEB VISIBILITY DATE On or about October 13, 2016
TOTAL AFFECTED VEHICLE COUNT USA: 82,067 CANADA: 32,465
APPROXIMATE REPAIR TIME Up to 110 TU
SPECIAL TOOLS NEEDED? SEE WORK PROCEDURE
PARTS REQUIRED SEE WORK PROCEDURE
INITIAL PARTS ALLOCATION DATE On or about October 11, 2016
EXPIRATION DATE NONE
ADDITIONAL INFORMATION IMPORTANT REMINDER ON VEHICLES AFFECTED BY SAFETY &
COMPLIANCE RECALLS
New Vehicles in Dealer Inventory: It is a violation of Federal law for a
dealer to deliver a new motor vehicle or any new or used item of motor
vehicle equipment (including a tire) covered by this notification under a
sale or lease until the defect or noncompliance is remedied. By law,
dealers must correct, prior to delivery for sale or lease, any vehicle that
fails to comply with an applicable Federal Motor Vehicle Safety Standard
or that contains a defect relating to motor vehicle safety.
Pre-Owned Vehicles in Dealer Inventory: Dealers are requested not to
delivery any pre-owned vehicles in their inventory which are involved in
a safety or compliance recall until the defect has been remedied.

**************************************************************************************************************

20Y6_12.2016
VOLKSWAGEN DEALERSHIP COMMUNICATION
Date: December 21, 2016
To: Dealer Principal, Sales Manager, Service Manager, Parts Manager and Warranty Administrator
Subject: Campaign Circular Revised – Safety Recall 20Y6 – Suction Pump
IMPORTANT NOTICE TO DEALERS – FOR IMMEDIATE DISTRIBUTION
On December 21, 2016 a revised campaign circular for safety recall 20Y6 will be available in Elsa and in ServiceNet.
Certain work instruction steps have been modified to help technicians avoid consequential damage during this repair.
Please alert everyone in your dealership about this revised information, including Sales, Service, Parts and Accounting personnel. Ensure any previous versions/copies you have printed or saved electronically are deleted.
If you have any questions or require additional assistance, please contact Warranty. As always, any press inquiries should be directed to Volkswagen Public Relations.
Volkswagen Customer Protection

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 16V-647
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Volkswagen Group of America, Inc. OCT 17, 2016 NHTSA Recall No. : 16V-647 Manufacturer Recall No. : 20Y6/20Y5 Manufacturer Information :
Manufacturer Name : Volkswagen Group of America, Inc.
Address : 3800 Hamlin Road
Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population :
Number of potentially involved : 110,042 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2015-2016 Audi A3 Cabriolet Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : NR
Descriptive Information : A3 Cabriolet: 1,975
1.8T FWD
Production Dates : JUN 06, 2014 – FEB 18, 2016
VIN Range 1 : Begin : WAU5CLFF2F1023290 End : WAU57LFF5G1085238 Not sequential Vehicle 2 : 2015-2016 Audi A3 Sedan Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : A3 Sedan: 26,000
1.8T
Production Dates : NOV 28, 2013 – FEB 24, 2016
VIN Range 1 : Begin : WAUCCGFF0F1000668 End : WAUA7GFF5G1086590 Not sequential Vehicle 3 : 2015-2016 Volkswagen Golf Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Golf: 25,890
1.8T
Production Dates : MAR 28, 2014 – MAR 15, 2016
VIN Range 1 : Begin : 3VW217AU9FM000730 End : 3VW217AU4GM051716 Not sequential Part 573 Safety Recall Report 16V-647 Page 2 Vehicle 4 : 2015-2016 Volkswagen GTI Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : GTI: 45,495
1.8T
Production Dates : DEC 06, 2013 – MAR 16, 2016
VIN Range 1 : Begin : 3VW4T7AU4FM000072 End : 3VW4T7AU8GM051723 Not sequential Vehicle 5 : 2015-2016 Volkswagen Golf SportWagen Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Golf SportWagen: 10,682
1.8T
Production Dates : OCT 21, 2014 – MAR 11, 2016
VIN Range 1 : Begin : 3VW217AUXFM500122 End : 3VWC17AU8GM520083 Not sequential Description of Defect :
Description of the Defect : The suction pump inside the fuel tank designed to purge fuel from the Evaporative Emissions (EVAP) system may be compromised resulting in fuel flowing directly into the EVAP system. If this happens, fuel could accumulate in the EVAP system and leak through the charcoal canister filter element.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Leaking fuel, in the presence of an ignition source, may result in a fire.
Description of the Cause : Due to a manufacturing issue, seal rings inside a suction pump in the fuel tank were assembled with too much tension. This could have pre-damaged the seals, potentially leading to fuel ingress into the EVAP system. Should the EVAP system be flooded, fuel could leak through the charcoal canister filter element. Identification of Any Warning
that can Occur : Customers could experience re-fueling issues (early stopping fuel nozzles, spillback) when fuel accumulated in the EVAP system. Fuel smell may also be noticed by the driver/vehicle occupants. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 16V-647 Page 3 Supplier Identification : Component Manufacturer
Name : ALFMEIER PRÄZISION AG
Address : Industriestr. 5
Treuchtlingen FOREIGN STATES 91757 Country : Germany Chronology :
July/Aug 2015: First failures were reported from the field and investigation was initiated.
Oct/Nov. 2015: Decrease of reported failures was noted and early failure of a limited number of components assumed. Failures were traced to automatic assembly process at supplier, possibly pre-damaging seal rings. Nov 2015: Assembly process was changed at supplier, field monitoring concluded.
Apr/May 2016: Increase of failures observed in the field. Vast majority reported from Puerto Rico. Analysis initiated as to why only Puerto Rico seems affected.
June/July 2016: High amount of aromatic compounds in Puerto Rico fuel identified as cause for excess failures. Additional failures observed in mainland USA.
August 26, 2016: The matter was brought to Volkswagen’s product safety committee and the presence of a defect was determined.
August 29, 2016: The matter was brought to Audi’s product safety committee and the presence of a defect was determined. Description of Remedy :
Description of Remedy Program : The potentially affected suction pump inside the fuel tank will be replaced.
Reimbursement should not occur as vehicles are still covered under New Vehicle Limited Warranty. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Supplier has changed from automated to careful manual assembly which removed the risk of pre-damage during assembly.
Parts went into Audi vehicle production in February 2016 and Volkswagen implemented into vehicle production in March 2016. Recall Schedule :
Description of Recall Schedule : Due to part supply limitations, VWGoA will stagger the mailing in waves
reaching from South to North due to temperature influence on failure rate. Rollout of Customer notification for repairs planned to begin 10/31/2016; interim customer notifications also planned to begin 10/31/2016.
Planned Dealer Notification Date : OCT 12, 2016 – OCT 12, 2016
Planned Owner Notification Date : OCT 31, 2016 – DEC 23, 2016
The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 16V-647
Page 4
The information contained in this report was submitted pursuant to 49 CFR §573
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 16V-647
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Volkswagen Group of America, Inc. OCT 04, 2016 NHTSA Recall No. : 16V-647 Manufacturer Recall No. : 20Y6/20Y5 Manufacturer Information :
Manufacturer Name : Volkswagen Group of America, Inc.
Address : 3800 Hamlin Road
Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population :
Number of potentially involved : 110,042 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2015-2016 Audi A3 Cabriolet Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : NR
Descriptive Information : A3 Cabriolet: 1,975
1.8T FWD
Production Dates : JUN 06, 2014 – FEB 18, 2016
VIN Range 1 : Begin : WAU5CLFF2F1023290 End : WAU57LFF5G1085238 Not sequential Vehicle 2 : 2015-2016 Audi A3 Sedan Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : A3 Sedan: 26,000
1.8T
Production Dates : NOV 28, 2013 – FEB 24, 2016
VIN Range 1 : Begin : WAUCCGFF0F1000668 End : WAUA7GFF5G1086590 Not sequential Vehicle 3 : 2015-2016 Volkswagen Golf Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Golf: 25,890
1.8T
Production Dates : MAR 28, 2014 – MAR 15, 2016
VIN Range 1 : Begin : 3VW217AU9FM000730 End : 3VW217AU4GM051716 Not sequential Part 573 Safety Recall Report 16V-647 Page 2 Vehicle 4 : 2015-2016 Volkswagen GTI Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : GTI: 45,495
1.8T
Production Dates : DEC 06, 2013 – MAR 16, 2016
VIN Range 1 : Begin : 3VW4T7AU4FM000072 End : 3VW4T7AU8GM051723 Not sequential Vehicle 5 : 2015-2016 Volkswagen Golf SportWagen Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Golf SportWagen: 10,682
1.8T
Production Dates : OCT 21, 2014 – MAR 11, 2016
VIN Range 1 : Begin : 3VW217AUXFM500122 End : 3VWC17AU8GM520083 Not sequential Description of Defect :
Description of the Defect : The suction pump inside the fuel tank designed to purge fuel from the Evaporative Emissions (EVAP) system may be compromised resulting in fuel flowing directly into the EVAP system. If this happens, fuel could accumulate in the EVAP system and leak through the charcoal canister filter element.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Leaking fuel, in the presence of an ignition source, may result in a fire.
Description of the Cause : Due to a manufacturing issue, seal rings inside a suction pump in the fuel tank were assembled with too much tension. This could have pre-damaged the seals, potentially leading to fuel ingress into the EVAP system. Should the EVAP system be flooded, fuel could leak through the charcoal canister filter element. Identification of Any Warning
that can Occur : Customers could experience re-fueling issues (early stopping fuel nozzles, spillback) when fuel accumulated in the EVAP system. Fuel smell may also be noticed by the driver/vehicle occupants. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 16V-647
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Supplier Identification : Component Manufacturer
Name : ALFMEIER PRÄZISION AG
Address : Industriestr. 5
Treuchtlingen FOREIGN STATES 91757 Country : Germany
Chronology :
July/Aug 2015: First failures were reported from the field and investigation was initiated.
Oct/Nov. 2015: Decrease of reported failures was noted and early failure of a limited number of components assumed. Failures were traced to automatic assembly process at supplier, possibly pre-damaging seal rings. Nov 2015: Assembly process was changed at supplier, field monitoring concluded.
Apr/May 2016: Increase of failures observed in the field. Vast majority reported from Puerto Rico. Analysis initiated as to why only Puerto Rico seems affected.
June/July 2016: High amount of aromatic compounds in Puerto Rico fuel identified as cause for excess failures. Additional failures observed in mainland USA.
August 26, 2016: The matter was brought to Volkswagen’s product safety committee and the presence of a defect was determined.
August 29, 2016: The matter was brought to Audi’s product safety committee and the presence of a defect was determined.
Description of Remedy :
Description of Remedy Program : The potentially affected suction pump inside the fuel tank will be replaced.
Reimbursement should not occur as vehicles are still covered under New Vehicle Limited Warranty. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Supplier has changed from automated to careful manual assembly which removed the risk of pre-damage during assembly.
Parts went into Audi vehicle production in February 2016 and Volkswagen implemented into vehicle production in March 2016.
Recall Schedule :
Description of Recall Schedule : Recall notification: TBD Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 16V-647
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Volkswagen Group of America, Inc. SEP 02, 2016 NHTSA Recall No. : 16V-647 Manufacturer Recall No. : TBD Manufacturer Information :
Manufacturer Name : Volkswagen Group of America, Inc.
Address : 3800 Hamlin Road
Auburn Hills MI 48326 Company phone : 1-800-893-5298 Population :
Number of potentially involved : NR Estimated percentage with defect : NR Vehicle Information : Vehicle 1 : 2015-2016 Volkswagen Golf/GTI/Golf Sportwagen Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : NR
Descriptive Information : Production Dates, VIN Ranges and Number Potentially Involved: TBD PZEV vehicles only
Production Dates : JAN 01, 1900 – JAN 01, 1900
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2015-2016 Audi A3 Sedan, A3 Cabrio Vehicle Type : LIGHT VEHICLES Body Style : ALL Power Train : NR
Descriptive Information : Production Dates, VIN Ranges and Number Potentially Involved: TBD 1.8T FWD
Production Dates : JAN 01, 1900 – JAN 01, 1900
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The suction pump inside the fuel tank designed to purge fuel from the Evaporative Emissions (EVAP) system may be compromised resulting in fuel flowing directly into the EVAP system. If this happens, fuel could accumulate in the EVAP system and leak through the charcoal canister filter element.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Leaking fuel, in the presence of an ignition source, may result in a fire. Part 573 Safety Recall Report 16V-647 Page 2 Description of the Cause : Due to a manufacturing issue, seal rings inside a suction pump in the fuel tank were assembled with too much tension. This could have pre-damaged the seals, potentially leading to fuel ingress into the EVAP system. Should the EVAP system be flooded, fuel could leak through the charcoal canister filter element. Identification of Any Warning
that can Occur : Customers could experience re-fueling issues (early stopping fuel nozzles, spillback) when fuel accumulated in the EVAP system. Fuel smell may also be noticed by the driver/vehicle occupants. Supplier Identification : Component Manufacturer
Name : ALFMEIER PRÄZISION AG
Address : Industriestr. 5
Treuchtlingen FOREIGN STATES 91757 Country : Germany Chronology :
July/Aug 2015: First failures were reported from the field and investigation was initiated.
Oct/Nov. 2015: Decrease of reported failures was noted and early failure of a limited number of components assumed. Failures were traced to automatic assembly process at supplier, possibly pre-damaging seal rings. Nov 2015: Assembly process was changed at supplier, field monitoring concluded.
Apr/May 2016: Increase of failures observed in the field. Vast majority reported from Puerto Rico. Analysis initiated as to why only Puerto Rico seems affected.
June/July 2016: High amount of aromatic compounds in Puerto Rico fuel identified as cause for excess failures. Additional failures observed in mainland USA.
August 26, 2016: The matter was brought to Volkswagen’s product safety committee and the presence of a defect was determined.
August 29, 2016: The matter was brought to Audi’s product safety committee and the presence of a defect was determined. Description of Remedy :
Description of Remedy Program : The potentially affected suction pump inside the fuel tank will be replaced.
Reimbursement should not occur as vehicles are still covered under New Vehicle Limited Warranty. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production : Supplier has changed from automated to careful manual assembly which removed the risk of pre-damage during assembly.
Parts went into Audi vehicle production in February 2016 and Volkswagen implemented into vehicle production in March 2016. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 16V-647
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Recall Schedule :
Description of Recall Schedule : Recall notification: TBD Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
* NR – Not Reported

SEOCONTENT-END